3 Order picking systems

Overview of pallet racking systems

Multi-position system

Usually 2, 3 or 4 pallets (or mesh boxes, steel boxes, etc.) are loaded per bay on an IPG pair of beams.

The system provides direct access to each pallet and is standard in forklift and AS/RS warehouses. Space is used in an optimal way with proportionately little frame, especially lengthwise (X direction).

Single-position system

Only one pallet (or mesh box, steel box, etc.) is stored per bay on a pair of pallet supports.

The height of each pallet bay can be individually adjusted to accommodate different good sizes and use space optimally. Each bay can of course be directly accessed.

Drive-in / drive-through racking system

Both systems are characterised by high use of space since on each channel up to 15 pallets and more can be stored per level.

In the drive-in system, the goods are loaded and unloaded on the same side (last-in first-out) while in the drive-through system, the goods are loaded on one side and unloaded on the other (first-in first-out).

Overview of flow storage systems

Push-back storage

LIFO (Last-in-First-out)

Optimal use of space

Storage according to type

Flow storage ...

FIFO (First-in-First-out)

Expiration dates, batches and production series can be optimally monitored.

Optimal use of space with dynamic block storage.

Separation of loading and unloading..

Internal transport paths are shortened.

... with order picking tunnel

Separation of the loading and picking zones.

Order by channel, unmixed storage of products.

Shorter picking routes and times.

Increase of the handling capacity

... with order picking platform and tunnel

All items in direct access.

Operational reliability by separating the loading and picking zones.

100% availability of goods through storage space management.

Maximum use of available space.

Stockpiling by double-deep storage.

Pick and flow levels

LIFO - Last-in first-out principle

The last-in first-out principle describes a warehouse organisation in which the goods taken into storage last are the first to be taken out again. This storage method is primarily used when several lots of identical goods are available in large quantities.

In this storage system, containers and products are removed on the same side of the rack as where they had been taken into storage. The LIFO method applies in particular to products with a fast turnover time where stocks are regularly completely depleted. This prevents the risk of obsolescence and spoilage of goods and products.

FIFO - First-in-First-out

The first-in first-out principle is used for goods that have a sell-by date or when monitoring changing production series.

In the FIFO principle, containers, boxes or cartons that were taken into storage first are also the first to be taken out again for further use. As a rule, this special form of storage is operated by forklift trucks or lift trucks on the lowest levels. To provide compliance with the corresponding withdrawal sequence, goods are stacked on one side of the rack and removed on the opposite side. Goods are transferred within the rack on gravity conveyor rollers (wheel conveyors) without needing any additional power.

AKL - Automated small parts storage system

Automated small parts warehouses (AKL) provide an extremely space-saving storage and order picking of small components in containers, trays or cartons.

Complete storage units of small parts are removed automatically and then transferred to the relevant order picking stations using a conveyor line connection. Tight tolerances mean AKL systems have to meet strict requirements in terms of specifications which require high-precision manufacturing and assembly.